Method and apparatus for constructing plaster board



v 27 192 Sept 7 c. R. BIRDSEY METHOD AND APPARATUS FOR CONSTRUCTING PLASTER B OARD Filed Jan. 13, 1921 4 Sheets-Sheet 1 gfkvam 707 J 41%; .P 434' m.

4 I 1,643,801 Sept. 1927' 0. R BIRDSEY METHOD AND APPARATUS FOR CONSTRUCTING PLAS TER BOARD Filed Jan. 13, 1921 4 Sheets-Sheet 2 27 1927. I Sept c. R. BIRDSEY METHOD AND APPARATUS FOR CONSTRUCTING PLASTER BOARD Filed Jan. 13, 1921 4 Sheets-Sheet 3 C. R. BIRDSEY METHOD AND APPARATUS FOR CQNSTRUCTING PLASTER BOARD Sept. 27,1927. 1,643,801-

Filed Jan. 1;, 1921 4 Sheets-Sheet 4 qwffw Patented Sept. 27, 1927-.

UNITED TATES CHARLES R. BIBDBEY, OI EINSDALE, ILLINOIS, ASSIGNOR TO UNITED STATES fimfl PATENT OFFICE.

COMPANY, OF CHICAGO, ILLINOIS, A CORPORATION OF ILLINOIS.

METHOD AND APPARATUS FOR CONSTRUCTING PLASTER BOARD.

Application med January 13, 1921. Serial No. 437,062

My invention belongs to that general class of inventions relating to the manufacture of plaster or wall board, and relates articularly to .the method and apparatus or constructing an im roved board. The inven tion has among its objects the production of an improved board and an improved method of constructing the same. It also has amongv its objects the production of a simple, eflicient, durable and satisfactory apparatus for carrying out the method herein described. Many other objects and advantages of the construction herein shown and described will be obvious to those skilled in the art from the disclosure herein given.

. To this end my invention consists in the novel" construction, arrangement and combination of parts herein shown and described, and more particularly pointed out in the claims.

In the drawings, wherein like reference characters indicate like or corresponding parts, K

Fig. 1 is substantially a view in elevatlon and partly in section, illustrating one form of apparatus suitable for carrying out th method;

Fig. 2 is a similar view illustrating a slight modification in the same for producing a reinforced edge;

Fig. 3 is atop elevation of the trimming mechanism shown in Figs. 1 and 2;

Fig. 4 is a view similar to Fig. 1, illustrating another modified form;

' boar with theedges not reinforced, which one typeof cutting-mechanism;

Fig. 5 is a similar view illustrating another form of apparatus;

Fig. 6 is a view in elevation illustrating the trimming mechanism shown in Figs. 4 and 5- F ig: 7 is a sectional view of the board under the forming rolls in Fig. 1;

Fi 8 is a sectional view of a portion of a may be produced with the apparatus shown in Figs. 1 and 4;

Fig. 9 is a similar view of a board having areinforced edge and Which may be constructed on the apparatus shown in Fig. 2 and 5; r FigllO IS a, view'in' elevation illustrating Fig. 11 is a plan view of the same; and Fig. 12 is an end elevation of the same.

Referring to thedrawings, it may be first mentioned that the boards shown in Figs. 8 and 9 are substantially similar, except that the board shown in Fi 9 is rein forced at theedges by. strips, r example trimmings removed from the sheets. Plaster boards of various types have been heretofore manufactured, some with what may be termed raw or unbound edges, and' others with bound edges, the board proper.-

of paper, which forms one cover sheet, and thereafter a second cover sheet applied, the,

board being generally passed through formin rolls wh1ch form the board and determine its thickness. Various other appliances and apparatus may be employed to finish the product. In some cases, as previously mentioned, the edges at the sides are bound by folding one of the sheets or its equivalent over the opposite side of the board so as to enclose the edge and produce a finished appearance.

In the manufacture of plastic board, the plaster mass dumped on the paper is, of course, to a large extent moist, as it must be of a consistency that it may be spread and be formed in the forming of the board; or as it may be explained, it is in an unstable condition.

Various kinds of paper or other covering material have been employed, and various conditions are met with as a result of this, owing to the expansion and contraction of the pap'er'and board, which may .vary dependmg upon the materials emtions in the. width of the paper, either in the different rolls or in the same roll, and

- frequently in handling the roll the paper becomes slightly telescoped. The paper contracts or expands in sh pment or storage and the ed es get abraded in handling. In the metho s previously carried out, it has been extremely difficult to produce a uniform production, owing to the reasons mentioned, and placin the u per sheet directly over the bottom sfieet, wlierebytheir edges are aligned or arranged one directly above the edge of the other sheet, so that either a poor y finished product was obtained,-or it was necessary to go to the expense of trimming the manufactured board after it had passed the forming rolls.

In my present method herein described, I trim the edges of the paper before assing through the machine, and preferab y in advance and comparatively close to the forming rolls so that the trimming mechanism may be so controlled andmanipulated as to trim the sheets and bring them with their edges exactly in alignment, so that when the board is taken from the machine,v

the edges are straight with the edges of the paper, arranged one directlyabove the other. Where the edges are to be reinforced, as will be hereinafter described, there is positively no Waste, as the trimmings are fed in so as 'to register with the outer covering sheets, thereby reinforcing the board at theed es, and producing an especially strong pro uct.

Referring to the drawings, particularly Fig. 1, 7 represents a table, sup ort or conveyor of a stationary or mova le type, as may be desired, and of the desired length.

i In the figure illustrated I have shown a movable conveyor belt which is carried by the end pulleys 9 and 10, and which may be driven in any suitable manner. There are also provided forming rollsll and 12 of the-desired size, shape and material, and which may be supported in any suitable manner, preferably so that they may be relatively adjusted so as to vary the thickness of the manufactured board. Arranged at each side of the conveyor are side boards or plates 13 which are the desired distance apart, this depending upon the size of the plaster board to be made. Preferably they are so spaced apart that the distance between them equals the width of the board, so that the covering sheets and plaster run between the same, whereby they accurately gauge the paper, one above the other, and at t e same time retain the laster, prevent its flowing out beyond the e ges and smooth the edges. The covering sheets, as before mentioned may be of any desired material, paper-bein generally employed for the purpose, whic paper is of the desired makeup and which is enerally supplied in rolls', thaL previously described.

for example, rol s 14 and 15 as shown in the figure. Arranfied betweenthe forming rolls and paper ro s are cutters 16 and 17,

' arranged to'cooperate and trim the opposite sides of the two covering sheets to the exact desired widths. These trimmers or cutters are made laterally adjustable so that the exact widths of the trimmed sheets and their exact location with reference to the edges and the plaster board machine into which it is being fed can be adjusted at the will of the operator. The trimmed off portions 2 and 3' at each side of the sheet shown in Fig. 3 are simply discarded and removed from time to time from the vicinity of the machine. I have shown cover sheet 2 extending over the conveyor, but cover sheet 3 I extend over a 'roll- 19 and under a roll 18. The same, after extending over the roll 19, is extended through a guide 20 of the desired size and shape, which feeds the same under the r oll 12 so that it may be applied as the top sheet of the board. It will be noted that the sheet is curved so that it is stiffened and consequently may be accurately fed to the plaster and bottom sheet. By separating the two sheets as shown in Fig. l, the plaster 21 may be applied between the sheets in the desired uan tities and mix. The top and bottom s eets being of exactly the same width at all times, they will also lap exactly over each other in a perpendicular position so that the edge of the top one is directly over the edge of the other.

Referring to Fig.2, the machine illustrated is substantially similar to that shown in Fig. 1 and the method practically the same, except the machine is here equipped to produce the board with the reinforced edge. This is accomplished b a guide 22 into which the en s 2 and 3 of the trimmings are fed and thence over between the sheets and into the body. The trimmings may be started in the guide, and inserted in the board by hand or any desired manner. After the trimmings have been properly started in between the sheets of the board, the same will be fed alon or drawn through b the advancing board and form an edge with the desired number of layers between the cover sheets, that is to say, one, two or more as desired. If additional reinforcing strips are desired other than the two trimmed edges at each side, additional strips may be fed in.

In the construction shown in Figs. 4 and 5, Fi 4 illustrates a modified type illustrate to make the board shown in Fig.8, while Fig. 5 illustrates substantially the same machine slightly modified to produce the board shown in Fig. 9. Referring to Fig. 4, the reference characters 7, 9, 10, 11, 12 and 13 represent mechanisms similar to K In this case, however, thelower sget 26 is taken from a roll 25, the same being trimmed to the desired width by the trimmers 27 arm [at each side, or equivalent mechanism for the purpose. Theupper sheet 29 is taken providing trated a guide 31 at each side into which the trimmings 26' may be'fed into and may be imbedded inthe plaster, and a similar guide 32 for guiding the trimmings 29 in the same manner. \Vith all of the constructions illustrated .it will be noted that the papers are trimmed substantially just before going through the forming rolls, so

'that they are practically in all cases the same exact width, it being possible to so control the trimming mechanism and method of trimming that they pass between the forming rolls in exactly the desired relation, thereby producing a uniform and attractive appearing product.

desired so that they may be controlled at the will of the operator or automatically to produce the desired product. Obviously any equivalent apparatus may beemployed to carry out the method or process described I have illustrated in Figs. 10, 11 and 12 one form of trimming mechanism in which the cutters are laterally adjustable relative the aper as well as relative each other, so that the trimming may be varied as found necessary, both in setting the machine and during the operation thereof Referring to these figures, 40 and 41, and. 42 and 43 represent the trimmers which may be of suitable size, shape, construction and material. The trimmers shown are mounted on shafts 44 and 45, the same being adjustable thereon, and the shafts may be driven by any suitable power or the paper only drawn therethrough. The shafts are rotatably carried by brackets 48 or their equivalent, Arranged to control the positions of the cutters are brackets 46 and 47 of the desired size, shape, construction and material.

, vided'with a hand wheel 50, which is operatively connected with one of the brackets, as'shown by bracket 46, so that the cutters may be adjusted in either directionlaterally in unison as desired. Obviously,

The varioustrimmers, as stated, are made adjustable as In the construction shown, the -j brackets 46 and 47 are operatively connected Obviously, by manipulating shaft by manipulating one or the other of the hand wheels 50 or 52, singly or by 0 erating them together in the same .or in ifierent directions, the cutters may be controlled 'either in unison or separately to produce the desired result. While I have illustrated but one form of trimming mechanism, the

same may be accomplished as desired.

With the board shown in Fig. 8, it will be noted that a straight edge or side 4 is a formed at each edge side of theboard, the extreme edges of the cover-sheets 2 and 3 being directly ali ned one above the other,

with a plastic bocfy which comes flush with the two edges of the covering sheets.

The reinforred board shown in Fig. 9 is substantially the same except that the trimmed portions 3' and- 2 are imbedded in the edges of the board, being so fed into the body as described, that their outer edgesare flush with the. extreme edges of the two covering sheets 2 and 3. Obviously, their widths will depend upon the width of the strips trimmed from the papers or covering sheets and may be made as desired depending upon the width of the separated product and the width of the paper supplied. It will likewise be obvious that any additional reinforcing strips may be inserted. It will be noted that in" this case, while the edges of' the board are reinforced, yet the main body of the board is not. divided or separated as in the case of wide sheets inserted between the cover sheets, the portions between one cover sheet and the trimmed portions 2' and 3 being connected with the body and with. each other. Either of the boards are extremely pleasing in a pearance .and also being true or perfectly ormed at the edges, and may be put together end to end or side to side as the case may be, the same giving a perfect. finished wall, ceiling or the like. With the form shown in Fig. 9, nails may be driven through more pieces of the fabric or covering material, and a slight crumbling between an of the reinforcing strips or covering sheets will not materially affect the strength of the edge nor the appearance. The same is also more durable showing that a better product is produced.

Having thus described my invention, it is obvious that various immaterial modifications may be made in the same without I departing from the spirit of my invention;

hence I do not wish to be understood as.

What I claim as new and desire to secure by Letters Patent is:

1. A"method of making a plaster board exact widths and a plying a body of plastic material between t em just after the trimming, and pressing the sheets and bod together to form a board of the desired ti ickness.

2. A method of making a plaster board consisting in bringing together and trimming a plurality of sheets of covering material at the same time to exact widths and applying a mass of plaster between them just after the trimming, and thereafter pressing ""thesheetsandmztss together to form a board of the desired thickness.

3. A method of making a plaster board consisting in bringing together and trimming two sheets at the same time to exact widths, applying a plastic mass on one sheet just after the trimming, and moving and pressing the sheets and mass together with the edges of theupper sheet positioned directly above and with its edge inalignment with the edge of the other sheet, and confining the plastic mass at the said edges between the sheets.

4. A method of making a plaster board consisting in bringing together and trimming two sheets at the same time to exact ual widths, applying a plastic mass of p aster on one 's set just after the trimming, and thence applying the second-sheet to the top of the plaster with its two side edges directly above the side edges of the lower first sheet, thence pressing the sheets the mass and yond the side e ges of the sheets and applytogether at the same time preventing the escape of the plaster at the edges.

. 5. A method of making plaster board consisting in bringing together and trimming at the same time two sheets of the same width, arranging said sheets one above the other, and ap lying a plastic mass between them just after the trimming, retaining reventing its escaping be- 7 mg pressure to the sheets to bring the two together with the plaster between them, with the side edges. of one directly aligned with the side edges of the other.

6. A method of making plaster board having a body and cover sheets adhering thereto, comprising the advancing of the bottom sheethtowards board formin trimming said sheet the exact wi th of the board desired as it advances, depositing the body in plastic form on the trimmed sheet,advancing the upper cover sheet towards the forming roll, trimming said sheet "placed together with and at the same time as the first sheet, the exact width .of the board desiredas it advances, applyingxthe said sheet over the bod passing the V dy and-cover sheets under t e forming roll, and maintaining the edges of the cover sheets in alignment one above the other and retaining the body inline therebetween.

'7. A method of making plaster board having a body with cover sheets adhering thereto, comprising bringin th -.7,

having a body with cover sheets adhering thereto, comprising bringing the sheets together and advancing them towards a board forming device, trimming both sheets at the same time the exact width of the board desired, depositing. the body in plastic form between said sheets just after the trimming, guiding the trimmed sheets to maintain their edges in alignment one above the other, passing the aligned sheets with the plastic body between them through board forming-rolls, and maintaining the plastic body between the aligned edges of the sheets.

9. A method of making plaster board with covering sheets and a plaster body arranged therebetween, consisting in first the side edges of the two sheets while to gether, whereby said sheets are both cut.

the same width, thence'separating the sheets and applying a plastic mass between them, thence again bringing the two sheets substantially together with the mass between, with the trimmed edges of one sheet lying directly above the trimmed edges of the other and forming the board of the desired thickness, at the same time preventing the escape of the lastic mass from between the sheets at t eir edges and preventing weavingof one sheet relatively to the other.

10. A method of making plaster board consistin in first trimming two sheets to exact wi ths, applying a plastic mass there between, and applying the. trimmings to desired relative widths, applying a plastic.

mass on one sheet and app ymg trimmings to the plastic mass at the edges of the sheets, whereby. the same are imbedded in themass and thereafter applying the other ing a plastic mass 'therebetween, and applying strips of the sheet material to the plastic mass and between the sheets adjacent the edges thereof, whereby the same are .im-

bedded in the mass, and thereafter pressing the sheets and plastic mass and strips to produce a board of the desired thickness.

14. A method of making plaster board 7 consisting in bringing together and at the same time trimming two sheets to the desired relative widths, applying a plastic mass on one sheet, applying strips of tibrous material to the plastic mass at. the

edges of the sheet, wherebthe same are imbedded in the mass, and t ereafter applying the other sheet, and pressing the sheets and plastic mass and fibrous strips together to produce a board of the desired thickness.

15. In a machine of the kind described and in combination, a suitable conveyor, means for applying sheets of covering material to the conveyor, means for trimming said covering sheets to equal widths whereby the sheets may be arranged with their side edges substantially in alignment,means for depositing a plastic mass on one sheet, means for conveying the other covering sheet onto said plastic mass, means for applying strips of material trimmed from said sheets by said trimming means to the plastic mass-between said sheets whereby the same is imbedded in the mass, and forming mechanism arranged at said conveyor for forming the coverlng sheets and plastic mass in a board of the desired thickness. 1 16. In a machine of the kind described an in combination, a suitable conveyor. means for applying sheets of covering material to the conveyor, means for trimming said covering sheets to equal widths whereby the sheets may be arranged with their side edges substantially inahgmnent, means for depositing a plastic mass on one sheet, means or 'conveying another covering sheet onto said plastic mass, means for applying strips of mate-' rial trimmed from said sheets by said trimming means to the plastic mass between said sheets whereby the same is imbedded in the mass, forming'mechanism arranged at said conveyor for forming the covering sheets and plastic mass in a board of the desired thickness, and means for confining the plas tic material between the sheets prior to its initial setting and smoothing the exposed I edges thereo 17. In a machine of the kind described and in combination, a suitable support, a forming mechanism arranged on said support, means for applying a sheet of covering material to the support, means for depositing a plastic mass on said sheet, means for conveymg a second-covering sheet onto said plastic. mass, said machine provided with means for bringing together and then trimming said cover sheets to desired relative widths, means for retaining the sheets in position whereby the sheets are arranged with their side edges substantially exactly in alignment. and means for applying strips of said sheet material to the plastic mass'between the sheets whereby the same are imbedded in the mass.

18. In a machine of the kind described and in combination, a suitable conveyor, means; for applying sheets of covering material'to the conveyor, means for bringing-together and then trimming said covering sheets to equal widths whereby the sheets'may be arranged with their side edges in alignment, means for depositing a plastic mass on one sheet, means for-conveying the other covering-sheet onto said plastic mass, and means for applying strips of coversheet material to the plastic mass between said sheets I whereby the same are imbedded in the mass, and formingmechanism arranged at said conveyor for 'forming the covering sheets and strips and plastic mass in a board of the desired thickness.

19. In a plaster board machine, forming,

mechanism, means for supplying cover sheets 1 mg cover sheets to said forming mechanism,

and means in advance of said forming mechanism for bringing together and trimming. the side edges of the sheets.

21. In a plaster-board machine of the kind described and in combination, forming mechanism, and means forbringing together and trimming sheets of cover materialsupplied to saidforming mechanism, whereby the sheets are fed into the forming mechanism in a predetermined manner relative to each other and gauged relative the forming mechanism, said trimming means being arranged at each side of the sheets for trimming the side edges of the sheets while they are in contact with each other whereby the sheets are fed .to the forming mechanism in a predetermined manner regardless of the imtial feeding of the same prior to trimming.

22. In a plaster board machine of .the kind. I

described and in combination a suitable support, formin mechanism, means for advancmg a cover s eet of cover material upon the said formin support, means for trimming said sheet the exact width of the board desired as it advances, means for advancing a second sheet of cover material to the forming mechanism, said second sheet being trimmed in contact and together with the first sheet as the advance the exact width of the board desire and means for passing both sheets through mechanism.

23. In a p aster board machine of the kind described and in combination, a suitable port, a. forming mechanism at said support, means for advancing cover sheets together towards said forming mechanism, mechanism mounted in advance of the forming mechanism for trimming the side edges of both sheets at the same time, while in contact, and means for depositing a plastic body between the sheets just after being trimmed and before passing through the forming mechanism.

24. In a plaster board machine of the character described and in combination, a suitable support, a forming mechanism at said support, means for advancing cover sheets together towards said forming mechanism, mechanism mounted in advance of the forming mechanism for trimming the side edges of both sheets at the same time while in contact, means for separating the sheets,

means for depositing a plastic mass between the trimmed sheets, and means bringing the sheets together and passin the'sheets with the plastic mass between tiem through the formin mechanism.

25. n a plaster board machine of the kind described and in combination, a suitable sup port, forming mechanism,- means for supplying cever sheet's to said forming mechanism, and mechanism at each side of the machine in advance of said forming mechanism for trimming the side edges of said sheets,'said trimming mechanism being lateraily adjustable in unison and independent 26 In a plaster board machine of the kind described and in combination, means for advancing cover sheets and bringing them together into contact before forming the board, and adjustable trimming cutters at each side to trim the cover sheet together at the same time while they are in contact.

In testimony whereof, I have hereunto signed my name.

CHARLES R. BIRDSEY. 

